Cover Stories English

Walki Group Customer Magazine
2015
BIG LEAP
WALKI IS SET FOR GROWTH
Comfy car rides with
Walki’s solutions!
Healthy buildings with
the right kind of insulation
Containing
heat challenges
IN T HE V INE YA RD
•
MINERAL OIL-FREE CEREALS
02 COVER STORIES 2015
04
BUILDING THE FUTURE OF CARS,
LAYER BY LAYER
Microphone wires are kept free from moisture
thanks to Walki's product.
08
KEEPING MINERAL OIL
AWAY FROM FOOD
Walki has a new innovative product for keeping
mineral oil away from what we eat.
12
MEMBRANE MOMENTUM
Insulation is key for energy-efficient buildings.
EDITORIAL 03
CONTENTS
10 Walki packages Swedish cookies
16 Investing in growth
18 The game-changing antenna
19 Refurbished Jatne plant
20 Tackling heat
22 Hard work in the vineyard
All set to meet market demand
Our job is to provide materials that make
our customers successful in their chosen
fields. To achieve this, we must meet our
customers’ expectations when it comes to
quality requirements, cost, lead times and
innovative products.
Our customers are accountable to
their customers, who sometimes might
be the very end consumers. We must
meet quality demands for buildings to be
energy-efficient yet moisture-free and
for food packaging to be safe. In many
businesses, speed is translated into
savings. So we work hard to cut our lead
times and are mindful, as we all are, of
keeping the costs down. We are able to
deliver on all these points, but the true
enabler of our strategy is innovation. We
must constantly push our boundaries
and chart unknown terrain to be able to
answer to our customers’ needs.
Our innovation efforts are instrumental
in achieving our growth ambitions.
The stories in this magazine all show
how Walki became a material science
company where innovation efforts
are driven by a goal we share with our
customers, namely resource efficiency.
For innovations to materialise into great
solutions, you need the right hardware
to support it. During the last year, we
have worked tirelessly to ensure that our
hardware – our plants – is up to the task.
We have invested heavily in our plants
in Poland, in Wroclaw and Jatne, and
COVER STORIES
Publisher
Leif Frilund
Editor-in-Chief
Marina Kurula
Editorial board
Kari Salminen, Ralph Mucha,
Arno Wolff
Editorial content and layout
Spoon Finland
Cover photo
iStock
Print
Forsberg 2015
Change of address
[email protected]
recently made a decision to invest in a new
production line in Valkeakoski to meet the
strong demand for our insulation facings.
After a period of lower economic
activity, especially in Europe, we see
a lot of growth potential in our chosen
segments, particularly in the construction
area and in consumer packaging,
however without forgetting our industrial
packaging solutions. We have invested
not only in our plants but also in the
development of our people’s skills and
capabilities, and we are now poised to
make our customers’ lives easier with new
innovations.
In summer Walki reached a milestone
by turning 85 years. It was on July 28,
1930, when the foundations for the
company, which later evolved into today’s
Walki, were laid. Although we are inspired
by our successful past, we do not want
to live in it. We have to keep on looking
ahead and pushing ourselves to find
innovative new ways of doing things.
As we go to press, we are still in the
process of divesting two plants – the
deal is subject to approval from the EU.
Regardless of the outcome our focus is
always on serving our customers in the
best possible way.
Thank you for taking an interest in our
stories!
Leif Frilund
CEO
04 INNOVATION
BUILDING
THE FUTURE
OF CARS,
LAYER
BY LAYER
text Sven Carlsson photo Dacia
WALKI COVER STORIES 2015
INNOVATION 05
Walki materials are
versatile. That means
that with a few tweaks
they can be utilized both
for packing solutions
or for adding value in
modern cars.
Walki’s polycrepe paper,
a perforated layer built into car
roofs, protects microphone wires
from moisture.
WALKI COVER STORIES 2015
06 INNOVATION
M
ost people probably conduct hands-free phone
conversations in their cars without thinking
of the layers of compact materials that make
it happen.
Among them is Walki’s polycrepe paper, a
light-weight, perforated layer built into car roofs to insulate
them from condensated water and protect electronic
features such as microphone wires.
Another important feature is sustainability. Walki’s
polycrepe is made of 80% natural fibres – previously it was
made of synthetic fibres.
”It’s a very simple but versatile product,” says Klaus Bründel,
Business Line Manager för Walki’s technical products.
”We apply a specific perforation to the product to make it
usable. Faurecia have four or five different layers they need
to put together with a big press to make the headliner, the
layer underneath the metal roof of a car. It’s sandwiched into
a very thin compression of materials – about three or four
millimeter thick,” Bründel said.
WALKI COVER STORIES 2015
The polycrepe paper has lead to a milestone for Walki:
a long-term automotive partnership with the French
automotive company Faurecia.
Walki offers Faurecia custom product development
that will take its innovations straight from the lab to the
manufacturer, where a consistent testing process ensures
before the new feature reaches the customer.
“Thanks to the direct cooperation with Faurecia
purchasing and development team, we have realized
together the qualification of Walkis Polycrepe into the final
application in less than 6 month. A key success factor in the
cooperation with Faurecia and for our future projects is the
right understanding of our customer’s demand to realise
product and process solution with clearly defined processes
and fast decision-making.”
The trend towards more economical cars, especially
electrical powered ones, has already started.
Hybrid cars, already commonplace in some markets,
require long battery lives. A crucial step on the way to the
INNOVATION 07
hybrid model of the future will be to make cars more energy
efficient – one of Walki’s strengths.
”We need to look at a solution to increase the heat
insulation,” says Bründel.
”That will save the electrical power needed to heat the cars
from inside. You save costs for every step of insulation.” ”
A key success factor in the
cooperation with Faurecia and
for our future projects is the
right understanding of our
customer’s demand to realise
product and process solution
with clearly defined processes
and fast decision-making.
You have to block the
passage of humidity that
comes from condensation.
Faurecia uses Walki’s
polycrepe paper for the
Romanian automaker
Dacia’s popular compact
SUV model.
Walki’s polycrepe paper – a problem-solver for Faurecia
Faurecia, a French parts giant was asked in 2014 to find a
solution to install microphones in the roofs of Dacias popular
SUV models.
”When we were in the process of vetting suppliers, we
got a contact at Walki from one of our employees in Russia,”
said Iván Arroyo Diestro, Commodity Buyer at Faurecia with
Walki as one of his accounts.
What began as a test run last year has now turned into a
full-fledged collaboration.
The French company has used Walki’s polycrepe paper
for the Romanian automaker Dacia’s popular compact SUV
model, which hit the market in 2010.
“Dacia needed a technical solution that would let them
incorporate the microphone, and we were able to provide it,”
Arroyo Diestro said.
”The film laminated with the paper stops humidity due to
condensation on the metal roof from passing through. That
way, it improves the isolation of the car,” he added.
Walki’s products and product developments have the
chance to become key in the future plans for Faurecia, which
supplies parts for one in four cars around the globe.
”What we expect from Walki is a good performance in
terms of quality, cost and delivery,” Arroyo Diestro said.
As well as one of Walki’s hallmarks: innovation.
”We expect Walki to propose innovations that can help
improve our product.”
WALKI COVER STORIES 2015
08 INNOVATION
KEEPING
MINERAL OIL
AWAY FROM
FOOD
Research shows that many packaged
foods contain mineral oil, which
is harmful to humans. Several EU
countries are looking into legislation
to prevent mineral oil migration.
Meanwhile, Walki has developed
Mineral Oil Safe Technology (MOST), an
efficient extrusion coating that keeps
mineral oil away from our food.
text Isabelle Kliger photo Walki
T
he country leading the debate surrounding mineral oil migration is Germany. Mirka
Nevala, Walki’s VP for Business Development,
believes the legislation could be introduced in
Germany as early as 2016 and it will pave the
way for EU-wide mineral oil regulations.
“Mineral oil contains Mineral Oil Aromatic Hydrocarbon (MOAH), which is especially harmful for humans
because our systems can’t break it down. It accumulates
in our bodies when we eat packaged food,” explains
Nevala.
Nevala recalls a TV programme that aired in Germany
a few years ago, in which a child was pictured with a large
glass of oil in front of her.
“The message was that this was the amount of oil the
little girl would consume in her lifetime, as a result of
eating packaged food like cereal, rice and pasta,” she says.
WALKI COVER STORIES 2015
The programme was prompted by a study led
by Dr Koni Grob and the Swiss Official Food
Control Authority. Grob’s study of 119 German food products remains the most relevant research on mineral oils to date, and
proves that there is a significant risk of
mineral oil contamination of dry food
from recycled fibre-based packaging
materials.
In the midst of the continuing debate
about the potential health risks, Walki has developed the most effective, state-of-the-art mineral-oil
protection product on the market. Aside from providing
an effective barrier against grease and water, like most
standard LDPE and HDPE coatings, Walki®Pack MOST
(Mineral Oil Safe Technology) is also glueable, sealable
and recyclable and provides a secure polymer barrier
against mineral oil contamination for recycled or virgin
fibre packaging solutions.
Walki®Pack MOST also offers a barrier against other
unwelcome substances that can be found in recycled
fibres, such as benzophenone, bisphenol A, DIPN and
softeners. Furthermore, its mineral oil barrier prevents cross-contamination originating from secondary
or other transport packaging made of recycled fibres.
Walki®Pack MOST has been approved for direct food
contact, in accordance with EU directive 10/2011.
“This product will enable the food-packaging industry to solve the growing issue of contaminated food,”
explains Stefan Erdmann, Technical Service & Development Manager for Walki’s Barrier Board products. “Food
companies and brand owners who adopt this product are
demonstrating their leadership and commitment to delivering safer food products to the marketplace.
“Customers can choose the board grade they prefer,
since Walki®Pack MOST works on all recycled fibre
board material available on the European market,” he
adds.
The effectiveness of Walki®Pack MOST has been
verified by independent research institutes, such as
INNOVATION 09
MINERAL FACTS
MOSH (Mineral Oil Saturated
Hydrocarbon) and MOAH (Mineral
Oil Aromatic Hydrocarbon) are
mineral oils commonly used in
industrial inks and are present
in printing dyes for newspapers
and packaging materials. Mineral
oil accumulates as a result of the
recycling of the raw materials
used for the production of paper
or cardboard packaging. A further
source for the contamination of food
with mineral oil may be jute bags
impregnated with mineral oil. There
are currently no maximum limits for
MOSH and MOAH in food according
to EU legislation.
VTT in Finland and Innoform in Germany, as well as
by renowned expert Dr Rainer
Brandsch from MDCTec Systems
GmbH.
“Once adopted, this packaging solution will allow ordinary people to buy and eat
delicious, healthy food, without being concerned about
their well-being,” says Erdmann.
”
This product will enable
the food-packaging
industry to solve
the growing issue of
contaminated food.
WALKI COVER STORIES 2015
10 INNOVATION
WALKI
PACKAGES
POPULAR
SWEDISH
COOKIES
When leading European packaging
manufacturer DS Smith needed
a new laminate for Gille’s
characteristic cookie packaging,
it looked no further than Walki.
text Isabelle Kliger photo Karl Vilhjalmsson
G
ille is one of Sweden’s best-loved brands of
cakes and cookies. With its colourful packaging and transparent lids, few brands are more
easily distinguishable.
“Over the last 30 years, this distinctive packaging has made Gille one of the most well-established,
easily recognisable food brands on the Swedish market,”
explains Morgan Stangenborn, Key Account Manager at
DS Smith, which manufactures corrugated board packaging solutions for Gille. “Its products are sold widely
both at home and abroad.”
In 2012, DS Smith decided to change the protective
laminate in Gille’s packaging.
“We wanted to be able to make the boxes with either a
black or white interior,” he continues. “We also needed a
laminate with an excellent grease barrier.”
When DS Smith’s previous supplier was not able to
meet these requirements, Morgan Stangenborn and his
colleagues turned to Walki.
WALKI COVER STORIES 2015
“Walki confirmed that they could help us. We’ve been
using their laminate now for more than three years and
believe it’s the best of its kind on the market,” says Stangenborn.
“In response to DS Smith’s request, we partnered
with them to develop a new product,” says Gustav Grahn,
Managing Director, Walki Sweden. “We carried out
extensive trials and tried several different solutions and
raw materials before settling on the final product.”
Walki-Line Ultra is a barrier liner that has been specially developed for use with corrugated board. As a
PET-paper sandwich liner, which, in this case, is based
on a virgin top liner, it provides outstanding protection
against grease, water and moisture. It is smooth, light and
strong, maintaining excellent packaging strength and
stiffness even in moist conditions and it is suitable for
direct contact with dry, wet and fatty foodstuffs.
Walki-Line Ultra can be pre-printed, is recyclable and
has good runability on a corrugating machine. It can be
INNOVATION 11
The Gille cookies are placed
in direct contact with the box,
placing greater demands on the
quality of the packaging.
made in a variety of colours and is currently available in black and
white. It can also be made in different grammages, based on various
liners and papers.
Stangenborn explains that the Gille packaging is unusual because the cookies are placed in direct contact with the box. This
places greater demands on the quality of the packaging.
“Since switching to the new solution, we haven’t had a single
claim for grease migration,” he says. “Apart from providing an excellent grease barrier – something that isn’t easily achieved with
foods containing coconut fat – we’re also delivering an excellent
level of food safety, as the laminate prevents unwanted substances
from migrating into the packaged product.”
“We used a new combination of raw materials to create a special
polymer layer, which guarantees food safety and provides an outstanding grease and moisture barrier,” adds Grahn. “In addition to
being extremely cost-effective, Walki-Line Ultra is also the most
secure barrier currently available on the market.”
”
Since switching to the new
solution, we haven’t had
a single claim for grease
migration.
WALKI COVER STORIES 2015
12 INNOVATION
WALKI COVER STORIES 2015
INNOVATION 13
Walki’s new breathable construction
membranes make for healthier buildings.
MEMBRANE
MOMENTUM
text Sami Anteroinen illustration White Tengbom Team
The new Karolinska
hospital is one of the biggest
construction sites in Europe.
WALKI COVER STORIES 2015
14 INNOVATION
Walki's breathable membrane
is composed of two layers
of polypropylene between a
monolithic film.
I
If you want to live in an environmentally friendly
house, make sure to capture heat. Saving energy is the
single most efficient way to make sure you are not further contributing to climate change.
However, combining energy savings and healthy
buildings is not always easy. Proper insulation is crucial,
but you need precise moisture control to avoid decay and
mould.
Thanks to a new breathable membrane developed by
Walki, you can keep the moisture level in the building in
control by letting vapour out. The membranes, composed
of two layers of polypropylene between the monolithic
film, allow moisture to go through them, preventing unwanted moisture from staying in the building. It’s far superior to the traditional microporous film when it comes
to withstanding both high and low temperatures: the
WALKI COVER STORIES 2015
membranes can withstand low temperatures reigning
outside the building and also tackle high temperatures,
which makes it suitable for walls and roofs where dark
cladding is used.
Another benefit is its solid durability – it retains its
structural characteristics for years to come.
Juho Hyytiäinen, Technical Service & Development
Manager, Construction Membranes, believes there is
huge potential for this type of next-generation insulation products.
“Building regulations are getting tighter all the time
and the focus is now on zero-emission houses. Our membranes help designers, architects and builders meet these
regulations more easily,” he says.
The project of developing a breathable Walki product
for roofing underlays started a couple of years ago, and
INNOVATION 15
Hospital luxury
”
Another benefit is its solid
durability - it retains its
structural characteristics
for years to come.
has now been approved for CE marking and has also
gained national approval in the Netherlands.
Michel Smit, Business Line Manager, Construction
Membranes, agrees that the time is right for this new wave
of highly engineered membranes. This is also reflected in
sales, which have grown steadily since the Dutch company Meuwissen was taken over by Walki in 2011.
While the perfect product for optimal moisture control exists now, consumers have been slow to jump on the
train. The construction industry, notoriously conservative,
is not a fast adopter of new things. This is a bit peculiar
when you consider the significance of air quality in people’s well-being. But then again, it’s much nicer to choose
tiles for your bathroom than think about insulation issues.
“When building a house, how much importance would
you give the vapor control layers versus kitchen fittings?”
Karolinska University Hospital is one of the biggest
hospitals in Europe. Responsible for specialised
health care in the Stockholm Council area, this is
where the most seriously ill patients are taken.
The hospital is now taking a big step towards being
the ‘University hospital of the future’ as the old
hospital is currently being rebuilt – and extended –
to become Sweden’s biggest hospital building. Set
to open its doors for the first stream of patients in
2016, the construction site is on of the biggest sites
in Europe.
The patients will be checking into a state-of-theart hospital. Perks include single rooms for all inpatient rooms equipped with shower and toilet, and
even a bed for relatives who want to spend the night.
Walki is supplying breathable membranes for
the walls, and there are plenty of those. The whole
building will have an area of approximately 330,000
square metres and will stand tall at 12 floors.
A strong focus on energy efficiency and
sustainability has been the guiding star throughout
the construction process at Karolinska.
“High quality and durability were cited as the
reasons why our product was chosen”, says Jens
Desthon, Sales Manager at Walki in Sweden.
The final bill for building the hospital, excluding
medical equipment, will be about 150 million euros.
You want your investment to last.
Hyytiäinen asks, making a point that people can willingly
spend a lot purely on cosmetic aspects, while forgetting
the fact that the house itself must be healthy for its inhabitants to stay healthy. Still, Hyytiäinen does not lay
the blame on consumers; it’s the industry that has failed
in its educational role, at least to some degree.
“We are talking about a conservative business, where
new ideas and products are not easily adopted. In that
sense, it’s good that governments are giving a gentle push
to the designers and builders.”
Michel Smit is confident that the new innovations for
breathable membranes will open attractive new markets
for Walki.
“We expect a great future for this new technology,
since the market is changing towards durable and airtight roofing membranes,” he sums up.
WALKI COVER STORIES 2015
16 NEWS
Henri Torkkola
inspects the quality
in the laboratory in
Valkeakoski.
INVESTING IN
GROWTH
text Sami Anteroinen & Lena Barner-Rasmussen photo Karl Vilhjalmsson
The jackhammer is hitting the asphalt
relentlessly outside Walki's Valkeakoski plant
in Finland. The first steps of a sizable new
investment at the plant are being taken.
A new production line is being added to the plant, and to
make it fit, the plant has to be expanded. Hence the jackhammer
at work. The next step is to tear down a wall to allow for the
expansion of the plant.
While the Valkeakoski plant is big on consumer products
like the indispensable carton cup we drink our coffee from
when we rush to work as well as packaging for the food and
pharmaceutical industry, the biggest growth is expected to
come from the construction industry. Although economic
growth has yet to recover in some parts of Europe, the outlook
for the housing market looks fairly bright.
The reason that lies behind this is EU's ambitions to curb
emissions. One important objective is the 20-20-20 target,
which aims, among other things, at a 20% improvement in
energy efficiency. This has a direct impact on the market
for insulation materials because keeping our houses warm
consumes a lot of energy. A well-insulated building can
make a big difference when it comes to energy consumption.
Multilayer-laminates, either with polyurethane or mineral
wool insulation, do the trick when it comes to capturing heat
inside our homes and keeping them energy-efficient.
WALKI COVER STORIES 2015
Top notch technology
With the new production line at Valkeakoski comes
the very latest technology too, ensuring
the highest
Better
capacity, faster
quality throughout the process.
delivery
times and superior
“The new production line will have
state-of-theart technology. For example we'll have
top-notch
quality.
That’s what customers
quality measurement and process control systems”,
get thanks to a new tandem
says Henri Torkkola, Technical Sales and R&D
line in
manager for flexible packaging at Walki
Oy.Wroclaw.
A stable level of humidity is important for keeping
the barriers in place when the customer uses the
material in their product. To make sure that the
quality is equally high throughout, each run is tested
in the laboratory at Valkeakoski.
“If you want to save money on your electricity bill, improve
insulation,” says Olivier Lucas, Business Line Manager, Construction Facings.
Construction of energy-efficient buildings is one driver, but
growth is also anticipated to come from the need to renovate
European houses.
“A lot of houses in Europe are currently not well protected
by insulation”, says Lucas.
This will further drive the demand.
“The demand for insulation is about to explode”, says Kari
Salminen, EVP Construction.
Broad know-how
That said, Valkeakoski has always been the company's most
versatile plant. The new production line will further add to the
diversity. This diversity translates into flexibility: whatever the
market needs, the Valkeakoski plant can adapt to the changing
demands.
So the new production line will be able to tend to whatever
demands customers might have.
"We will have more flexibility when it comes to deliveries,
and our product offering will be more diverse"; says Heikki
NEWS 17
Kari Salminen, Heikki
Lumme and Henri Torkkola
welcome more capacity.
What's up
in Garstang?
Desmond Murphy is a seasoned packaging industry guy
– he's been his entire career in this industry, mainly in the
corrugated sector. After working for different companies
in the industry he's now stationed in the UK, running
Walki's plant in Garstang.
? How are things in Garstang?
Walki`s business in Garstang has so far been doing
well in 2015. Our sales volumes are increasing. We are
currently reviewing ways of becoming more efficient so
that we can achieve better output.
? What can you do even better?
We need to constantly enhance our skills in the plant
in order to support the volume growth. Our lead times
need to be competitive – ie. short – so that we can offer
good customer service. We also constantly need to
focus on quality through out the process.
Lumme, Business Line Manager, Flexible Packaging.
“The production line can cater to several different product
segments in addition to the main segment construction
products, such as flexpack and medical products. The
extrusion possibilities are also vast”; adds Salminen.
Thanks to the new production line, the Valkeakoski plant will
be able to run new barriers on products, and Lumme, Torkkola
and Salminen are keen on continuing investigating new solutions
together with customers with the aim of expanding their product
portfolio and enabling them to grow in new markets.
"We will be even better equipped than before to develop
new products that help our customers succeed in their
markets," says Salminen.
The capacity will also be increased thanks to the new
production line.
"We will substantially increase our capacity in all our
product segments. This means that we can guarantee short
delivery times as we can respond swiftly to customers’ needs
with tailor-made solutions," says Torkkola.
The new production line will be up and running during the
first quarter of 2016, and customers can expect deliveries
shortly after that.
? What motivates you the most?
I'm driven by achievement and success. I strongly believe
in teamwork, because every individual is important to a
successful business.
? What can you do in Garstang when you have some
time off?
Garstang is located in central Lancashire, not far from
the beautiful English Lake District and only 15 miles from
the Seaside town of Blackpool, so everyone will find
something to do.
WALKI COVER STORIES 2015
18 NEWS
The Pietarsaari
plant is now ready for
a quick ramp-up as the
processes and materials
are now in place.
THE GAME-CHANGING
ANTENNA
text Sami Anteroinen photo Walki
Walki®4E is ready for big things.
Expect affordable and sustainable
antennas on paper material.
Sipi
Savolainen
thinks that
the paper
antennas are
real gamechangers.
“4E offers a new sustainable and cost-efficient antenna material for the RFID (Radio-Frequency IDentification) market
and for inlay manufacturers specifically.
“Currently, RFID inlay manufacturers are using etched PET
antennas for their inlays. Our technology enables – for the first
time – affordable and sustainable antennas on paper material,”
says Sipi Savolainen, Business Line Manager for 4E Technology at Walki.
He points out that the introduction of new technology always takes time, but there is a strong consensus on the market
that paper antennas are a real game changer. Presently, there
are qualification processes going on at the customer sites and
preparations are being internally for market growth and highvolume manufacturing.
“Processes and materials are now in place for a quick rampup of the production in the Pietarsaari plant,” Savolainen says.
Product for the future
The four E’s of Walki®4E stand for efficiency, economy, ecology
and exactness. Compared with etching, the technology eliminates a whole step from the tag production process (or from the
converter’s process), thus combining efficiency and economy.
Since paper is used as a substrate, the RFID manufacturers can
leave out the insertion of the PET inlay into paper altogether.
“Efficiency and economy revolve around providing lower
price levels for the inlay manufacturers,” confirms Savolainen.
And then there are the environmental benefits. The absence
WALKI COVER STORIES 2015
of liquid chemicals leaves the RFID manufacturers with an endproduct that is 100% recyclable: made of paper and aluminium
only, the antenna it is easily recycled in a fibre recycling process, where metal detectors sort out the aluminium.
The final ‘E’, exactness, means that the precision of the
laser-cutting of the patterns allows for smaller chips, greater
repeatability in the production process and higher accuracy
of the antenna.
“Exactness is important when chips get smaller in the future – etching technology or printing technology is not able to
achieve our accuracy levels,” says Savolainen.
One million strong
Chinese company Shang Yang RFID Technology Yangzhou has
been collaborating with Walki since 2013, performing two specific trial runs with Walki engineers to try out 15 different kinds
of Walki paper/PET antennas. According to Marketing Manager Michael Wu, more than a million inlays for customers, who
use Walki antennas, have been assembled during this time.
“We have witnessed great progress in the Walki paper antennas,” says Wu.
“We have gained a lot of new knowledge and the production
process of paper antennas has improved through these experiments, which also helped us to grab the chances to present a
new type of inlay products to our customers with Walki paper
antennas.”
Wu believes that as the Walki paper antenna provides stable
performance after being made into an inlay, this is a “remarkable advantage” in comparison with other paper-based antenna
technology options.
“The Walki antenna has already built on its unique characteristics in the market, and I believe it will be successful.”
NEWS 19
LEANER AND
CLEANER IN
JATNE
Tomasz
Kusowski is
happy with the
refurbished
Jatne plant.
text Sami Anteroinen & Lena Barner-Rasmussen photo Walki
The Jatne plant used to be a
very crowded place. But that’s all
changed now, thanks to a new
modernisation project.
The Jatne plant has always specialised in supplying the
paper industry with the packaging for copy paper, so some of
its production lines were used for manufacturing corrugated
boxes. But this process creates quite a lot of dust and takes up
space too. On top of that, the main customer for the corrugated
boxes has their premises a fair drive from Jatne. So to make life
easier for them, box production was moved to the newly
opened Walki plant in Kwidzyn.
This change brought with it many other benefits.
With the Jatne plant so crowded, Walki needed to rent
production and warehouse space in a building close by.
Although situated next door, it was still an extra step in the
whole production process. So a new warehouse was built, that
connects to the Jatne plant’s main building.
“By removing corrugated box production, we gained a lot of
extra space. This meant that we could house all of our extrusion and printing machines in one hall,” explains Tomasz
Kusowski, Director of the Jatne, Kwidzyn and Svetogorsk
plants. “We now have all our operations under one roof. The
production process begins from the extruder, where we coat
the paper with polyethylene. Then we take it to the printing machines and finally to the warehouse, where the finished product
waits to be shipped to our customers. The whole production
process is leaner and cleaner.”
The new 1,700 m2 logistics warehouse also drives efficiency
improvements throughout the entire operation, while
emphasising a ‘safety first’ environment. For example, raw
materials are now stored closer to the production facility, and
with automation from production to packaging, this means less
forklift traffic.
But the centre-piece of the refurbishment project is the
new Flexo printing machine, from Spanish supplier Comexi.
This 10-colour, high-end printing press enables Jatne to print
packaging designs for the most demanding customers. The
new Flexo also brings efficiency improvements, with a printing
speed exceeding 300 meters per minute, as well as a much
No reckless tearing
needed with Walki's
perforated strip.
shorter change-over time compared to the older machines.
Another key investment at Jatne is the Tear Strip machine,
which provides a new, much more convenient method of
opening the packaging on reams of paper, and is the first
product of its kind on the European market. The machine
incorporates a perforated strip into the ream wrapper, allowing
for easy opening by end-users. In contrast, the current wrapper
design often leaves it ripped, requiring further means of
storage for the paper. But with a tear strip, the integrity of the
packaging remains intact. The Tear Strip machine also opens
up exciting new options in ream wrapper design, for drawing
the eye to the tear strip. The machine was developed in close
cooperation with our customers.
“The investment in the Tear Strip machine shows how
important both Jatne and Poland are to Walki, and how we’re
always open to collaborate with our customers to find optimal,
innovative solutions. Tear Strip packaging is well established
in North America, but we are the first to offer it to European
customers,” says Kusowski.
As part of Jatne’s transformation, it was also decided to
eliminate solvent-based inks from the printing process and
replace them with water-based inks, which is the standard at
all Walki plants. This helped improve the working environment
at Jatne, as not only is the risk of explosion or fire much higher
with solvent-based inks, but they also create a distinct smell
which makes for an unpleasant work environment. On top of
that, water-based inks are much more environmental-friendly
products, making the modernized Jatne plant cleaner in every
sense. WALKI COVER STORIES 2015
20 INNOVATION
TACKLING
HEAT
Certain cargo is more sensitive
than others. You want
your chocolate to arrive in
perfect condition. Walki helps
customers manage heat
challenges, whether we
are talking about housing
insulation or sensitive cargo.
text David Nikel photo EcoCool
Using innovative Walki materials,
German company EcoCool produces
thermal blankets and insulated shipper
boxes for a wide range of logistics clients,
reducing the need for fully refrigerated
solutions on trucks and aeroplanes.
The insulation product produced by
Walki, Isohood 2L2, is simply double-layer
bubble film coated with aluminium. The
product was originally invented to be used
as housing insulation (and it continues
to be used for the same), but it was soon
EcoCool's thermal blankets
reflect IR-radiation. Heat is kept in
during transportation of sensitive
chemicals in winter, while heat
is kept out during air cargo for
sensitive pharmaceuticals.
WALKI COVER STORIES 2015
INNOVATION 21
discovered that the material worked well
as a thermo-covering.
Effective insulation when it
matters most
EcoCool's thermal blankets reflect
IR-radiation, keeping heat in for the
transportation of sensitive chemicals
during winter, and heat out when used
as an air cargo cover for sensitive
pharmaceuticals. Quantifying the exact
insulation effect is difficult, but as a
rule of thumb, a difference of around
10°C between inside and ambient
temperatures can be expected for about
three hours.
EcoCool also uses the Isohood 2L2
material to insulate shipper boxes,
ranging from a low-cost solution for the
parcel shipment of foodstuff to long
range distribution of pharmaceuticals.
Partnership within Walki
“This product is a good example of
innovation and cooperation within Walki
group,” explains Steven Verheul, Sales
Manager at the Haarlem plant in the
Netherlands.
“The Valkeakoski plant in Finland
provides us with a regular supply of
lacquered aluminium from a different
business area that we combine with
bubble film here at Haarlem. We deliver
the material to EcoCool and they stitch it
into covers and make it ready for use for
their customers.”
Continuous improvement
Expansion in the home food delivery
market and increased regulation in the
pharmaceutical industry drive a growing
industry demand. To retain and build
on their market share, EcoCool request
continuous improvements from Walki,
both in insulating properties and costeffectiveness of the products. Walki has
trialled around 20 variants of materials
and production methods to stay ahead of
the emerging competition.
“We are very happy with the
partnership with Walki,” says EcoCool's
Florian Siedenburg.
“The team at Haarlem, led by Steven
Verheul, plays a vital part in our success,
supplying us with a constant stream
of sample materials to test. We have a
personal and friendly relationship with
Walki, which we highly appreciate. We
know that we place high demands on
them with varied volumes from our side,
but over the years they have found a way
to never let us down.”
What's Up in Haarlem
Jan van den Brink has been with Walki for a little over a
year, but he has a vast experience from running different
types of plants.
? What are you up to at the plant in Haarlem?
We produce mainly construction membranes,
insulation material and industrial packaging. The
volumes for industrial packaging have slightly
increased compared to last years. The construction
business has been slow the last years, and
we see a clear upturn now in the construction
market, especially the housing market. Consumer
confidence is rising and the amount of house
permits is growing rapidly. Walki develops new
products for the construction market and this will
lead midterm to increasing sales.
? Any challenges?
We just finished a big refurbishment of our 3,2
metre wide extrusion line where we renewed all
drives, upgraded the Siemens PLC software from S5
to S7 and renewed the gauging system. This meant
working with three suppliers and making sure that
we could deliver to our customers on time. Thanks
to a constant dialogue with the customers and a
dedicated logistics department we were able to
manage quite well.
? You've been with Walki for about a year now.
What is your impression of the company?
Industry applications
Pharmaceuticals. Ever-increasing regulation of the pharmaceutical industry
means managing temperature during transportation is a priority. Insulated
shipping boxes can keep temperatures stable for up to 96 hours.
Online food delivery. The increase in coverage of online supermarket
deliveries has caused a growth in demand for insulated delivery boxes. They
are a cost-effective way for supermarkets to keep food fresh, especially
items such as chocolate that are sensitive to changes in temperature.
Aviation. Amsterdam Airport and Lufthansa take advantage of thermal
blankets to improve their capability to transport temperature-sensitive
cargo over long distances.
Walki is a medium-sized international company
and this means that we have short communication
lines within the group. The people that work here
are honest, open and pragmatic and that is a very
pleasant atmosphere.
? What would you recommend for people to do
when visiting Haarlem?
Walk through the old center, eat or drink something
at the numerous restaurants and bars, take a small
boat tour and visit the Frans Hals museum to see the
painters from the Golden Age of the Netherlands.
The oldest museum of Holland, Teyler’s Museum, is
also nice.
WALKI COVER STORIES 2015
22 PROFILE
HARD WORK
IN THE
VINEYARD
text Lena Barner-Rasmussen photo iSTOCK & Manfred Ertle
When he was young, Manfred Ertle's father had to
gently force him out to help in the family's vineyard.
These days it is his preferred place to be.
F or several years, Manfred Ertle worked during the
weeks in the sales office and later at the Steinfurt
plant, and only came home for the weekends to
the Palatinate Wine Route, where he grew up
and still lives. Not so anymore. These days the
Consumer Packaging Export Sales Manager, responsible
for Austria, Eastern & Southern Europe and Overseas
markets, works mainly from home. And when he’s done for
the day, chances are that you’ll find him outside checking
on his grapes. Together with his father and brother-in-law,
he produces up to 5,000 litres of wine per year.
Manfred Ertle grew up in the Palatinate area in
southern Germany. It is a typical wine area – Manfred
lives about 20 kilometres from the French border. About
35 years ago, Manfred’s father decided to get a vineyard
of his own, and today there are three vineyards on the
family property. Manfred, his father and brother-in-law
are each responsible for their own vineyard even though
they rely on each other for help. Together, they produce
two white wines, Riesling and Müller Thurgau, and a red
wine called Dornfelder.
“We will also start producing Merlot soon,” he adds.
WALKI COVER STORIES 2015
In the winter months there is not much happening,
but come March the action begins. The first task that
needs to be done is the cutting of the branches.
“It is the first action you take to influence the quality
of the wine. This is later followed by cutting the grapes
too,” explains Manfred.
Later on in May, once the grapes have grown a bit, you
do another round of cutting followed by some fertilisation.
The next round of hard work comes in early autumn, when
the harvest season begins. During the summer, you hope
the weather gods won’t be too fickle. The grapes need a lot
of sun and the occasional rain shower.
“The worst that can happen is frost in the early stages
of growing. We experienced that four years ago and in
one of the vineyards 95 per cent of the crop was lost,
which meant no harvest.”
After the harvest it's time for the actual wine making.
You start by pressing the grapes in a wine press and then
you carry out a first quality control to make sure you are
in the right direction. That’s also when you enjoy the new
wine and follow the fermentation process. Then comes
the filtration process before the wine is finally bottled.
PROFILE 23
WINE FACTS)
Europeans consume an average of 30 litres
per person per year.
European consumption accounts for almost
70 per cent of global consumption, making Europe
the most important wine market in the world.
The largest producer countries are Italy, France and
Spain, producing about 80 per cent of all European
wine. Germany is the fourth-largest producer
in Europe.
Manfred Ertle
Manfred Ertle relies on external help for bottling and
quality control. Germany has quite strict wine laws to
limit the possibility of influencing the quality by mixing
other ingredients into the wine.
One thing you can do to influence the quality is
limiting the quantity of grapes by cutting.
“Sometimes less is more.”
The year 2012 was a particularly good year for the Ertle
family’s red wine.
These days Manfred enjoys the work in the vineyard.
“I like to be outside, alone with the wildlife. Sometimes
I'll see a pheasant or even a fox, and I can hear the birds.
It is a very nice break from a hectic workday,” he says.
It hasn’t always been like this. In his youth, he would
reluctantly join his father who prodded him out to work.
And now Manfred has the same experience with his
18-year-old son.
“At that age you are usually interested in other things.
I wouldn't say I have to force my son to help me, but I do
have to work hard to convince him to join me,” he says
with a laugh.
Maybe in a couple of years that will change too. Hanging out in the vineyard wasn't
Manfred Ertle's favourite pastime in his
teens. These days it is.
3
QUESTIONS
Do you enjoy wine from other countries as well? Yes, I do. I enjoy wines from France, Chile and
South Africa. You can find some excellent wines
from those countries.
What is your favourite wine?
For a white, I enjoy a good Riesling that I will drink
with asparagus grown in this area or with white
fish. With wild meat I usually enjoy a good bottle of
Merlot or Bordeaux.
Do you grow anything else besides grapes?
I don't but my parents do. They have a big kitchen
garden with fruit and berries of all kinds.
WALKI COVER STORIES 2015
Construction • Consumer Packaging • Industrial Packaging
Upstream solutions
for downstream opportunities
Tailored to your individual needs.
Walki Group
At Walki, we’ve created protective packaging solutions for a wide range
of industries for decades. In everything we do, we aim to maximise performance by
using the minimum amount of raw materials, working sustainably to minimise our
impact upon the environment. This is the way we’ve worked in the past and it’s the
way we’ll work in the future.
To find out how we’ve got your business covered go to www.walki.com